Carl Valentin DPM IV Reference guide

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Carl Valentin GmbH

Postfach 3744

78026 Villingen-Schwenningen

Neckarstraße 78 – 86 u. 94

78056 Villingen-Schwenningen

Phone

Fax

+49 7720 9712-0

+49 7720 9712-9901

E-Mail

Internet

info@carl-valentin.de

www.carl-valentin.de

Copyright by Carl Valentin GmbH / 7968081.0519

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Quick reference guide and

product safety

English

DPM IV

56

English

Copyright by Carl Valentin GmbH.

Information on the scope of delivery, appearance, performance, dimensions and weight reflect our knowledge at the time of

printing.

We reserve the rights to make modifications.

All rights, including those regarding the translation, are reserved.

No part of this document may be reproduced in any form (print, photocopy or any other method) or edited, copied or distributed

electronically without written permission from Carl Valentin GmbH.

Due to the constant further development of our devices discrepancies between manual and device can occur.

Please check www.carl-valentin.de for the latest update.

Trademarks

All named brands or trademarks are registered brands or registered trademarks of their respective owners and may not be

separately labelled. It must not be concluded from the missing labelling that it is not a registered brand or a registered trademark.

Carl Valentin direct print modules comply with the following EU directives:

• EG Low-Voltage Directive (2014/35/EU)

• EG Electromagnetic Compatibility Directive (2014/30/EU)

Carl Valentin GmbH

Postfach 3744

78026 Villingen-Schwenningen

Neckarstraße 78 – 86 u. 94

78056 Villingen-Schwenningen

Phone

Fax

+49 7720 9712-0

+49 7720 9712-9901

E-Mail

Internet

info@carl-valentin.de

www.carl-valentin.de

DPM IV

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Contents

Intended Use

56

Safety Notes

56

Decommissioning and Dismantling

57

Environmentally-Friendly Disposal

57

Operating Conditions

58

Unpack/Pack the Direct Print Module

61

Installation and Initial Operation

61

Install the Print Mechanics at Machines

61

Connect the Pneumatic Power Supply

62

Connect the Direct Print Module

62

Before Initial Operation

62

Print Control

63

Print Settings

63

Load Transfer Ribbon

63

Touch-Screen Display

64

Technical Data

65

Clean the Transfer Ribbon Tension Roller

68

Clean the Printhead

68

Zero Point Adjustment

68

DPM IV

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English

Intended Use

• The direct print module is solely intended to print suitable media which have been approved by the manufacturer. Any

other or additional use is not intended. The manufacturer/supplier is not liable for damage resulting from misuse. Any

misuse is at your own risk.

• Intended used includes heeding the operating manual, including the maintenance recommendations/regulations specified

by the manufacturer.

• The direct print module may only be used while in proper working order and for the intended purpose. Users must be safe,

aware of potential dangers and must comply with the operating instructions. Faults, in particular those which affect safety,

must be remedied immediately.

• The direct print module is a state-of-the-art device which complies with the recognized safety-related rules and regulations.

Despite this, a danger to life and limb of the user or third parties could arise and the direct print module or other property

could be damaged while misusing the device.

Safety Notes

• The direct print module is designed for power supply systems of 110 … 230 V AC. Connect the direct print module only to

electrical outlets with a ground contact.

NOTICE!

The protective earthing conductor of the socket is to be examined by a qualified technician.

• Couple the direct print module to devices using extra low voltage only.

• Before making or undoing connections, switch off all devices involved (computer, printer, accessories etc.).

• Operate the direct print module in a dry environment only and do not get it wet (sprayed water, mist etc.).

• Do not operate the direct print module in explosive atmosphere and not in proximity of high voltage power lines.

• Operate the direct print module only in an environment protected against abrasive dust, swarf and other similar impurity.

• Maintenance and servicing work can only be carried out by trained personnel.

• Operating personnel must be trained by the operator on the basis of the operating manual.

• Depending on use, ensure that clothing, hair, jewellery and similar personal items do not contact the exposed rotating parts

and/or the moving parts (e.g. print carriage).

• The print unit and parts of it (e.g. motor, printhead) can get hot during printing. Do not touch the printhead during operation.

Cool down the print unit before changing material, removal or adjustment.

• Never use highly inflammable consumables.Carry out only the actions described in these operating instructions. Any work

beyond this may only be performed by the manufacturer or upon agreement with the manufacturer.

• Unauthorized interference with electronic modules or their software can cause malfunctions.

• Other unauthorized work or modifications to the direct print module can endanger operational safety.

• There are warning stickers on the direct print modules that draw your attention to dangers. Therefore the warning stickers

are not to be removed as then you and others cannot be aware of dangers and may be injured.

DANGER!

Danger to life and limb from power supply!

 Do not open the casing.

CAUTION!

Two-pole fuse.

 Before opening the housing cover, disconnect the device from the mains supply and wait for a moment until the

power supply unit has discharged.

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NOTICE!

For Norway and Sweden

Devices which are attached via a power connector with a connection to safety earthing to the safety earthing of the

electric equipment of the building and to a cable distribution system with coaxial cables can cause fire risks under

certain circumstances. Therefore the connection with a cable distribution system must be made by a device which

provides an electric insulation underneath a specific frequency range.

Decommissioning and Dismantling

NOTICE!

The decommissioning of printing system can only be carried out by trained staff.

CAUTION!

Danger of injury by imprudent handling when lifting or placing the printing system. Risk of crushing by

unexpected linear movement of the printing carriage.

 Do not underestimate the weight of the printing system (9 … 16 kg).

 Do not lift the printing system at the hood.

 Protect the printing system against uncontrolled movement.

Environmentally-Friendly Disposal

Manufacturers of B2B equipment are obliged to take back and dispose of old equipment that was manufactured after 13 August

2005. As a principle, this old equipment may not be delivered to communal collecting points. It may only be organised, used and

disposed of by the manufacturer. Valentin products accordingly labelled can therefore be returned to Carl Valentin GmbH.

This way, you can be sure your old equipment will be disposed of correctly.

Carl Valentin GmbH thereby fulfils all obligations regarding timely disposal of old equipment and facilitates the smooth reselling

of these products. Please understand that we can only take back equipment that is sent free of carriage charges.

The electronics board of the printing system is equipped with a battery. This must only be discarded in battery collection

containers or by public waste management authorities.

Further information on the WEEE directive is available on our website www.carl-valentin.de.

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Operating Conditions

Before initial operation and during operation these operating conditions have to be observed to guarantee save and

interference-free service of our devices.

Therefore please carefully read these operating conditions.

As the delivery is customised, please compare the supplied accessories with your order.

General Conditions

Shipment and storage of our devices are only allowed in original packing.

Installation and initial operation of our direct print modules is only allowed if operating conditions were fulfilled.

Commissioning is prohibited until it can be established that, where relevant, the machine into which the partly completed

machinery is to be incorporated complies with the provisions of Machinery Directive 2006/42/EC.

Initial operation, programming, operation, cleaning and service of our direct print modules are only recommended after careful

study of our manuals.

Operation of direct print module is only allowed by especially trained persons.

NOTICE!

Organise trainings regularly.

Content of the training are the chapters 'Operating Conditions', 'Loading Media' and 'Maintenance and Cleaning'.

These indications are also valid for someone else's equipment supplied by us.

Only use original spare and exchange parts.

Please contact the manufacturer with respect to spare/wear parts.

Conditions for Installation Place

The installation place of direct print module should be even, free of vibration and currents of air are to be avoided.

The direct print module have to be installed to ensure optimal operation and servicing.

Installation of Power Supply

The installation of the power supply to connect our direct print modules has to be effected according to the international rules

and regulations, especially the recommendations of one of the three following commissions:

• International Electronic Commission (IEC)

• European Committee for Electro technical Standardisation (CENELEC)

• Verband Deutscher Elektrotechniker (VDE)

Our devices are constructed according to VDE and have to be connected to a grounded conductor. The power supply has to be

equipped with a grounded conductor to eliminate internal interfering voltage.

Technical Data of Power Supply

Power line voltage and power line frequency:

see type plate

Allowable tolerance of power line voltage:

+6 % … −10 % of nominal value

Allowable tolerance of power line frequency:

+2 % … −2 % of nominal value

Allowable distortion factor of power line voltage:

≤ 5 %

Anti-Interference measures:

In case your net is infected (e.g. by using thyristor controlled machines) anti-interference measures have to be taken. You can

use one of the following possibilities:

• Provide separate power supply to our direct print modules.

• In case of problems please connect capacity-decoupled isolation transformer or similar interference suppressor in front of

our direct print modules.

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Stray Radiation and Immunity from Disturbance

Emitted interference according to EN 61000-6-3: 01-2007

Immunity to interference according to EN 61000-6-2: 03-2006

NOTICE!

This is a machine of type A. This machine can cause interferences in residential areas; in this case it can be required

from operator to accomplish appropriate measures and be responsible for it.

Connecting Lines to External Machines

All connecting lines have to be guided in shielded lines. Shielding has to be connected on both sides to the corner shell.

It is not allowed to guide lines parallel to power lines. If a parallel guiding cannot be avoided a distance of at least 0.5 m has to

be observed.

Temperature of lines between: −15 … +80 °C.

It is only allowed to connect devices which fulfil the request 'Safety Extra Low Voltage' (SELV). These are generally devices

which are checked corresponding to EN 62368-1.

Installation of Data Lines

The data cables must be completely protected and provide with metal or metallised connector housings. Shielded cables and

connectors are necessary, in order to avoid radiant emittance and receipt of electrical disturbances.

Allowable lines

Shielded line:

4 x 2 x 0,14 mm² ( 4 x 2 x AWG 26)

6 x 2 x 0,14 mm² ( 6 x 2 x AWG 26)

12 x 2 x 0,14 mm² (12 x 2 x AWG 26)

Sending and receiving lines have to be twisted in pairs.

Maximum line length:

with interface V 24 (RS232C) - 3 m (with shielding)

with USB - 3 m

with Ethernet - 100 m

Air Convection

To avoid inadmissible heating, free air convection has to be ensured.

Limit Values

Protection according IP:

65 (for control unit with option protective cover)

Ambient temperature °C (operation):

min. +5

max. +40

Ambient temperature °C (transport, storage):

min. −25

max. +60

Relative air humidity % (operation):

max. 80

Relative air humidity % (transport, storage):

max. 80 (bedewing of devices not allowed)

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Guarantee

We do not take any responsibility for damage caused by:

• Ignoring our operating conditions and operating manual.

• Incorrect electric installation of environment.

• Building alterations of our direct print modules.

• Incorrect programming and operation.

• Not performed data protection.

• Using of not original spare parts and accessories.

• Natural wear and tear.

When (re)installing or programming our direct print modules please control the new settings by test running and test printing.

Herewith you avoid faulty results, reports and evaluation.

Only specially trained staff is allowed to operate the direct print modules.

Control the correct handling of our products and repeat training.

We do not guarantee that all features described in this manual exist in all models. Caused by our efforts to continue further

development and improvement, technical data might change without notice.

By further developments or regulations of the country illustrations and examples shown in the manual can be different from the

delivered model.

Please pay attention to the information about admissible print media and the notes to the direct print module maintenance, in

order to avoid damages or premature wear.

We endeavoured to write this manual in an understandable form to give and you as much as possible information. If you have

any queries or if you discover errors, please inform us to give us the possibility to correct and improve our manual.

DPM IV

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Unpack/Pack the Direct Print Module

CAUTION!

Danger of injury by imprudent handling when lifting or placing the printing system. Risk of crushing by

unexpected linear movement of the printing carriage.

 Do not underestimate the weight of the printing system (9 … 16 kg).

 Do not lift the printing system at the hood.

 Protect the printing system against uncontrolled movement.

 Check the direct print module for transport damages.

 Remove the foam transportation safeguards near the printhead.

 Check delivery for completeness (see operating manual).

NOTICE!

Retain original packaging for subsequent transport.

Installation and Initial Operation

NOTICE!

Important information on installing can be found in the operating manual (the complete documentation is included in

the scope of delivery on CD-ROM, and can also currently be found on our website).

NOTICE!

Starting from an angle of inclination > 30°, the optionally available brake (A) is mandatory.

Install the Print Mechanics at Machines

NOTICE!

Only trained and qualified technical personnel may carry out installation.

A

C

A

D

B

• At the side parts of print mechanics (C) are two M6

threads (D) on the upper and back side which can be

used for the attachment of print mechanics to a

machine. The maximum thread depth is 12 mm.

• The connecting cable (A) to control unit can be led from

the printing system to top or to the side.

• The pneumatic tube Ø 8 mm (B) can be led from the

printing system alternatively to top or to the side.

NOTICE!

When using a counter-pressure plate that does not come from the manufacturer, the conditions of the operating manual

have to be observed.

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Connect the Pneumatic Power Supply

The pneumatic power supply for the printhead mechanics has to be made available a minimum continuous pressure of 4 …

6 bars in front of the pressure regulator. The maximum pressure in front of the pressure regulator is 10 bars and 4 bars after the

pressure regulator.

NOTICE!

A pneumatic power supply of 4 … 6 bars is recommended.

Druckmechanik

Druckluftversorgung

Pneumatikschlauch

min. 4 bar, max. 7 bar

Druckregler mit Manometer

Print mechanics

Pneumatic power supply

Pneumatic tube 8x1

Pressure regulator with manometer

Please observe the following notes:

• The compressed-air has to be dry and oil free.

• The supplied pressure regulator with manometer is to

connect with a plastic tube Ø 8 mm via a plugging

bolting to the pneumatic power supply. The

connection between pressure regulator and print

mechanics is established by a pneumatic tube Ø 8

mm and an appropriate push-in fitting.

• Position pressure regulator as near as possible to the

print mechanics.

• The pressure regulator is only to operate in the

direction of the arrow (see label at pressure

regulator). The direction shows the way of the

streaming air.

• It is not allowed to bend the plastic tubes.

• Shortening of the plastic tubes has to be made with a

clean right-angled cut without squashing the tube. If

necessary use special tools (available in pneumatic

requirements).

• Keep the pneumatic tube as short as possible.

Connect the Direct Print Module

The direct print module is equipped with a versatile power supply unit. The device may be operated with a mains voltage of

110 … 230 V AC / 50 … 60 Hz without any adjustments or modifications.

CAUTION!

The direct print module can be damaged by undefined switch-on currents.

 Set the power switch to '0' before plugging in the direct print module.

 Insert the plug of power cable into a grounded electrical outlet.

NOTICE!

Insufficient or missing grounding can cause faults during operation.

Ensure that all computers and connection cables connected to the direct print module are grounded.

 Connect the direct print module to computer or network with a suitable cable.

Before Initial Operation

 Mount the print mechanics.

 Connect all cables between print mechanics and control unit.

 Protect the cables against unintentional unscrewing.

 Connect the compressed air line.

 Connect the control unit and PC by printer interface.

 Connect the control unit and the packaging machine by inputs and outputs.

 Connect the power cable of control unit.

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Print Control

As the direct print module is always in control mode, print orders can only be transmitted but not started via the existing

interfaces (serial, USB or Ethernet). The print is started by a start signal to the ‘print start-control input’. So that the control unit

detects when the start signal can be set, it is possible and mostly necessary to track the print status via the control outputs.

Initial Operation

 After all connections are completed, switch on the control unit.

 Insert the transfer ribbon (see description below).

Load Transfer Ribbon

NOTICE!

Before a new transfer ribbon roll is loaded, the printhead must be cleaned using printhead and roller cleaner

(97.20.002).

The handling instructions for the use of Isopropanol (IPA) must be observed. In the case of skin or eye contact,

immediately wash off the fluid thoroughly with running water. If the irritation persists, consult a doctor. Ensure good

ventilation.

A

B

D

C

• Open the cover of print mechanics.

CAUTION!

Risk of scraping when inserting the transfer

ribbon res. when removing the used transfer

ribbon!

 Be careful with the bearing plate edges!

• Load a new transfer ribbon roll (A) onto the unwinding unit (B)

and push it until it stops.

NOTICE!

Please observe that the color of the transfer ribbon is

on the outside.

• Load an empty rewinding roll (D) onto the rewinding unit (C)

until it stops.

• Load the transfer ribbon according to the illustration

• Stick the transfer ribbon with an adhesive tape to the empty

roll and tighten the transfer ribbon with some turns of the roll.

• Close the cover of print mechanics.

CAUTION!

Risk of crushing and damage to objects when

closing the dust cover!

 When closing the dust cover, ensure that

neither parts of the body nor objects (e.g.

clothes, jewelery) are clamped!

NOTICE!

As for the electrostatic unloading the thin coating of the thermal printhead or other electronic parts can be damaged,

the transfer ribbon should be antistatic.

The use of wrong materials can lead to printer malfunctions and the guarantee can expire.

CAUTION!

Impact of static material on people!

 Use antistatic transfer ribbon, because static discharge can occur when removing.

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Touch-Screen Display

Touch-screen display structure

The touch-screen display shows an intuitive graphic user interface with well-

defined symbols and buttons.

The touch-screen display informs about the current device status and status of

the print order, alerts in case of an error and indicates the device settings in the

menu.

The desired settings are made by selecting the buttons on the touch-screen

display.

Favorites

Display favorites list

Configuration

Selection of parameter settings

Memory Card

Memory card access menu

Print

Starting print job

Test Print

Starting test print

Formfeed

Starting layout feed

Info

Indication of device information

Current date and time

Device name (indicated in

network)

Transfer ribbon status

Customized info field

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Technical Data

DPM IV 53

DPM IV 107

DPM IV 128

Print width

53,3 mm

106,6 mm

128 mm

Print lengths

140 mm, 240 mm, 340 mm, 447 mm, 570 mm, 630 mm

Print resolution

300 dpi

Print speed

50 … 500 mm/s

Back speed

50 … 700 mm/s

Printhead

Corner Type

Acoustic Emission (measuring distance 1 m)

Average sound pressure level

75 dB(A)

Transfer Ribbon

Ink

outside or inside

Max. roll diameter

85 mm

Core diameter

25.4 mm / 1″

Max. length

450 m

Max. width

55 mm

110 mm

130 mm

Dimensions (width x height x depth)

Print mechanics

(with cover)*

(print length + 230 mm) x

188 mm x 265 mm

(print length + 230 mm) x

188 mm x 320 mm

(print length + 230 mm) x

188 mm x 340 mm

Control unit

314 mm x 230 mm x 80 mm (without connection lines)

Weight

Print mechanics

ca. 9 … 16 kg (depending on print length/print width)

Control unit

ca. 5,5 kg (ohne Anschlussleitungen)

Connection cable

ca. 0,85 kg (print mechanics – control unit)

Electronics

Processor

High Speed 32 Bit

RAM

16 MB

Slot

Compact Flash card type I

Battery Battery cache

for Real-Time clock (storage of data with shut-down)

Warning signal

accoustic signal when error

Interfaces

Serial

RS-232C (up to 115.200 Baud)

USB

2.0 High Speed Slave

Ethernet

10/100 Base T, LPD, RawIP-Printing, DHCP, HTTP, FTP

2 x USB Master

connection for external USB keyboard and memory stick

Connection Values

Pneumatic connection

min. 6 bar dry and free from oil

Air consumption typical*

* hub 1,5 mm

150 cycle/minute

6 bar operating pressure

150 ml/min

300 ml/min

Nominal voltage

110 … 230 V AC / 50 … 60 Hz

Nominal current

110 V AC / 3 A - 230 V AC / 1.5 A

Fuse values

2x T4A 250 V

Operation Data

Temperature

5 … 40 °C

Humidity

max. 80 % (non-condensing)

* identical with DPM IIIxi

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Operation Panel

Touchscreen Display

color display, 800 x 480 pixel

screen size 7"

Operating functions

Favorites, function menu, memory card, print start, test print, feed, about menu

Settings

date, time, shift times

11 language settings (others on demand)

print and device parameters, interfaces, password protection

Monitoring

Stop printing if

end of ribbon

end of layout

Status report

extensive status print with information about settings

e.g. print length counter, runtime counter,

photocell interface and network parameters

printout of all internal fonts and all supported bar codes

Fonts

Font types

6 Bitmap fonts,

8 Vector fonts/TrueType fonts,

6 proportional fonts

other fonts on demand

Character sets

Windows 1250 up to1257, DOS 437, 850, 852, 857

all West and East European Latin, Cyrillic, Greek

and Arabic (option) characters are supported

other character sets on demand

Bitmap fonts

size in width and height 0,8… 5,6

zoom 2 … 9

orientation 0°, 90°, 180°, 270°

Vektor fonts/TrueType fonts

size in width and height 1 … 99 mm

variable zoom

orientation 0°, 90°, 180°, 270°

Font attributes

depending on character font

bold, Italic, inverse, vertical

Font width

variable

Bar Codes

1D bar codes

CODABAR, Code 128, Code 2/5 interleaved, Code 39, Code 39 extended, Code 93,

EAN 13, EAN 8, EAN ADD ON, GS1-128, Identcode, ITF 14, Leitcode, Pharmacode,

PZN 7 Code, PZN 8 Code, UPC-A, UPC-E

2D bar codes

Aztec Code, CODABLOCK F, DataMatrix, GS1 DataMatrix, MAXICODE, PDF 417,

QR Code

Composite bar codes

GS1 DataBar Expanded, GS1 DataBar Limited, GS1 DataBar Omnidirectional, GS1

DataBar Stacked, GS1 DataBar Stacked Omnidirectional, GS1 DataBar Truncated

all bar codes are variable in height, module width and ratio

orientation 0°, 90°, 180°, 270°

optionally with check digit and human readable line

Software

Configuration

ConfigTool

Process control

NiceLabel

Design software

Labelstar Office Lite

Labelstar Office

Windows printer driver

Windows 7® - Windows 10® 32/64 Bit,

Windows Server 2008® (R2) - Windows Server 2019®

Technical details are subject to change.

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Cleaning

DANGER!

Risk of death by electric shock!

 Before opening the housing cover, disconnect the device from the mains supply and wait for a moment until the

power supply unit has discharged.

NOTICE!

When cleaning the printing system, personal protective equipment such as safety goggles and gloves are

recommended.

Maintenance task

Frequency

General cleaning.

As necessary.

Clean the transfer ribbon drawing roller.

Each time the transfer ribbon is changed or

when the printout is adversely affected.

Clean the printhead.

Each time the transfer ribbon is changed or

when the printout is adversely affected.

Replace the printhead.

In case of errors in printout.

Adjust the angle.

In case of an unequal use of the printhead.

NOTICE!

The handling instructions for the use of Isopropanol (IPA) must be observed. In the case of skin or eye contact,

immediately wash off the fluid thoroughly with running water. If the irritation persists, consult a doctor. Ensure good

ventilation.

General Cleaning

CAUTION!

Abrasive cleaning agents can damage the direct print module.

 Do not use abrasives or solvents to clean the outer surface of the printing system.

 Remove dust and paper fuzz in the printing area with a soft brush or vacuum cleaner.

 Clean the outer surfaces with an all-purpose cleaner.

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Clean the Transfer Ribbon Drawing Roller

BA

A soiled drawing roller can lead to reduced print quality and can

affect transport of material.

• Open the cover of print mechanics.

• Remove the transfer ribbon from the direct print module.

• Remove deposits with roller cleaner and a soft cloth.

• If the roller (A) appears damaged, replace it.

Clean the Printhead

BA

Printing can cause accumulation of dirt at printhead e.g. by colour

particles of transfer ribbon, and therefore it is necessary to clean the

printhead in regular periods depending on operating hours, environmental

effects such as dust etc.

CAUTION!

Printhead can be damaged!

 Do not use sharp or hard objects to clean the

printhead.

 Do not touch protective glass layer of the printhead.

• Open the cover of print mechanics.

• Remove the transfer ribbon.

• Clean the printhead surface with a special cleaning pen or a cotton

swab dipped in pure alcohol.

• Before using the printing system, let the printhead dry for about two

to three minutes.

Zero Point Adjustment

A

B

C

• Move the start position of the printing carriage (A) with

the slider (B).

• If the slider is at shaft end (side panel), the maximum

print length is available.

• By adjusting the printer zero point, the usable print area

is shortened.

• Use the zero point adjustment for adjusting the print

position onto the foil.

• The zero point monitoring is made by an inductive

proximity switch (C).

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Carl Valentin DPM IV Reference guide

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